Spray dyeing pile fabrics



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FIG. '2 uARRY lYf fa m United States Patent 3,271,102 SPRAY DYEING PILEFABRICS Harry L. Morgan, Collegeville, Pa., assignor to James Lees andSons Company, Bridgeport, Pa., a corporation of Delaware Filed Nov. 24,1961, Ser. No. 154,430 4 Claims. (Cl. 8-451) This invention relates tospraying equipment and to an improved method for spraying color ontorunning lengths of textile material having a pile surface.

The application of color in the sense of dyeing to textile fabrics andother materials is, of course, well known. One manner in which 'colorcan be applied to such materials is by means of a spray or jet of dyecarried by a liquid vehicle. However, in the case of pile fabrics suchas floor coverings having substantial pile depth, no method norapparatus has been capable of achieving level dye application anduniform penetration of the pile. If the liquid dye is applied insuflicient quantities and under sufficient pressure to the pile fabricwhen flat, it has been found that by using excessive quantities ofmaterials in high pressure, the outer face of the pile can be penetratedwith reasonable satisfaction. However, the base of the pile does notreceive the proper dye penetration and the result is, therefore,unsatisfactory. This disadvantage increases in proportion to the piledepth and is also affected by such factors as pile density, type ofyarn, twist, etc.

A primary object of the present invention, therefore, is to provide animproved procedure for spray dyeing color onto a running length of pilefabric.

A further object of the invention is to provide an improved apparatusfor opening up the pile during a liquid spray treatment of a runninglength of fabric.

A further object of the invention is to provide in a process forcontinuously spray dyeing a running length of pile fabric suitableliquid pre-treatment which assists in obtaining adequate penetration ofthe dye liquid to the base of the pile yarns.

A still further object of the invention is to provide an integratedliquid application and setting apparatus for continuously treating,dyeing, and finishing a running length of pile fabric.

Further objects will be apparent from the specification and drawings inwhich:

FIGS. la-ld show schematically the apparatus constructed in accordancewith the present invention,

FIG. 2 is an enlarged section of one of the liquid application chambersof FIG. 1 and as seen at 2-2 of FIG. 3,

FIG. 3 is a top view partly broken away of the structure of FIG. 2,

FIG. 4 is an enlarged detail of the pile penetrating liquid applicationstation as seen at 4-4 of FIG. 2,

FIG. 5 is a section of the structure of FIG. 4 as seen. at 5-5,

FIG. 6 shows a modification of the liquid applying manifold shown inFIG. 4,

FIG. 7 is a section as seen at 7-7 of FIG. 6,

FIG. 8 is a sectional detail of a modification of the structure of FIG.5,

FIG. 9 is an enlarged sectional detail as seen at 99 of FIG. 2,

FIG. 10 is a section as seen at 10-10 of FIG. 9,

FIG. 11 is a side view of one of the liquid beater stations shown inFIG. 1, and

FIG. 12 is an end view of the structure of FIG. 11.

The invention comprises essentially the provision of a continuous fabrichandling machine having a plurality of liquid applying chambers throughwhich the running length of fabric passes and having two liquidapplicaice tion stages in each chamber. The first chamber is utilized toapply certain preliminary materials which assist in the applicationandpenetration of the liquid dye. The second chamber is utilized toapply the color or dye. In each chamber the first stage involves adevice for breaking the fabric over a sharp radius to permit penetrationof the liquid to the base of the pile. The second stage in timedsequence applies liquid to the flattened fabric to produce a levelapplication of liquid to the pile surface whether pre-treating chemicalsor color.

Referring now more particularly to the drawings, the apparatus forapplying liquid to pile fabrics constructed in accordance with thepresent invention comprises a first liquid applying chamber 20 throughwhich the fabric F is fed from a beam or roll 21 which may be mounted onany convenient stand 22. A driven conveyor belt 23- is trained over aseries of rollers 24, 25, 26, and 27 in such a way that the upper passof belt 23 carries the fabric F from end to end through chamber 20. Asthe fabric enters the chamber it passes under a guide element or bar 30,thence upwardly and over an opening member 31, and thence under a secondguide or bar 32. The fabric then travels in a fiat condition along theconveyor 23 and under the second stage liquid application spray 33. Thefirst stage liquid application is applied at 34 directly above theopening or breaking element 31. Suitable exhaust ducts are supplied andmay be connected to the chamber 20 at 35. These elements are not shownin detail since they form no part of the present invention. From chamber20 the fabric F passes over a first beater station 37 comprising a pairof spaced guide elements 38 and 39 which straddle a rotating beaterassembly 40. The fabric then passes directly into the second liquidchamber 41 which is constructed in the same way as chamber 20.Corresponding primed reference numbers are used for the details ofchamber 41 since these two are substantial duplicates. The fabric thenpasses from chamber 41 onto the second beater assembly 42 which likewiseis the same or similar to the beater assembly 37. Corresponding partshave been given primed numbers in FIG. 1b. In chamber 20 the fabric isheated with certain preliminary liquids to assist in the application andpenetration of the color which is applied in chamber 41. In each casethe same liquid is applied through the spray manifolds 33 and 34 whereasthe color is applied through manifolds 33' and 34'.

After the preliminary liquid treatment in chamber 20 and the applicationof color in chamber 41 as well as suitable removal of excess liquid. inbeater assembly 42, the fabric F passes to a steam chamber 45 where itis festooned over a series of lower rollers 46,. 47, and 48 and upperrollers 49 and 50. With proper application of heat in the steamer thefabric is passed through a series of wash boxes 51, 52, and 53, each onehaving a plurality of lower rollers 54, 54 and upper rollers 55, 55.Squeeze rollers 56 and 57 are mounted at the trailing edge of each washbox to reduce the liquid run-01f in each phase. From the wash boxes thefabric is fed through a pair of squeeze rolls 60 and 61 mounted in rollstand 62. These squeeze rollers 60 and61 remove any additional liquidthat may remain after treating in the wash boxes. The fabric then passesover a third beater assembly 63 and through a tenter-drier assembly 64having a conventional tenter frame 65 carried over rollers 66, 67, 68,and 69. The fabric after drying may then be handled in any desiredmanner but is preferably wound in rolls such as on roll stand 71.

In the composite liquid treating and finishing apparatus described abovethe steamer wash boxes and drier are all conventional pieces of.equipment well known in the art and require no further detaileddescription. The liquid applying chambers and 41 are a particularlyimportant feature of the invention and they, together with the detailsof the beater assembly, will be described in greater detail.

Referring now to FIGS. 2-5, each of the chambers 20 and 41 comprises ahousing mounted on suitable columns or pedestals 76, 76. The conveyor 23is driven by means of a suitable motor 77, reduction unit 78, and adriving connection 79 to roller 25. Roller 30 under which the fabricfirst passes is suitably journaled in pillow blocks 80, 80 and thebreaking element 31 is supported in an elevated position on a series ofstandards 81, 81. Roller 32 is similarly journaled in pillow blocks 82,82. The relationship between the height of breaking 82,82. Therelationship between the height of breaking member 31 and thelongitudinal distance between centers 30 and 32 determines the angle atwhich the fabric F passes over the element 31 and consequently thedegree to which the pile will be opened up at this station. In the firststage of liquid treatment, whether pre-treating liquids or color, thefluid is supplied through a mainfold 83 from which a series of nozzlesor jets 84, 84 depend. In a preferred form, manifold 83 is stationarybut this mainfold may be oscillated transversely of the fabric as willbe described more clearly in connection with FIGS. 6 and 7.

After passing under roller 32 the fabric is again deposited on theconveyor 23 and subjected to further liquid spray treatment from aseries of traversing liquid nozzles or jets 85, 85 connected to aminifold 86 and having a series of flexible liquid hoses 87, 87 attachedto each nozzle. The manifold 86 is suspended from a post 90 clamped inyoke 91 which traverses back and forth on tracks or ways 92 and 93 on aseries of upper rollers 94, 94 and lower rollers 95, 95 (FIGS. 9 and10). All of the flexible hoses 87, 87 are connected through a valve 96mounted on top of yoke 91 and having an actuating handle 97. A chain 100is trained over an idler sprocket 101 adjustable by means of a chaintightener assembly 102 and at the other end over a driving sprocket 103keyed to the shaft 104 of a gear reducing unit 105. The yoke 91 isdrivingly connected to chain 100 through an angle bracket and pin 91a.Unit 105 is driven from a motor 106 through belt 107, pulley 108, and anadjustable sheave 109. Both the motor 106 and the reduction unit 105 aremounted on an upper cross member 110 secured to standards 76a and 76b.As the manifold and yoke oscillate transversely of the chamber, thedirection of travel is reversed at the end of each pass by means ofappropriate limit switches 111 and 112 also mounted on standards 76::and 76b, respectively. The spraying of the liquid is automaticallystopped near the end of one pass by means of an adjustable flat cam 113secured to a plate 114 and mounted on brackets 115 and 116. The properadjustment is achieved by means of the elongated slots in the cam 113 aswell as the plate 114. When the valve handle 97 contacts cam 113 at theend of the righthand pass as seen in FIG. 9, valve 96 is closed to stopfurther spraying of liquid. A similar cam is mounted at the other sideof cross member 110 and is likewise adjustable in plate 121 and brackets122. This insures that the liquid spray stops as soon as the manifold 86has passed each edge of the fabric thus avoiding unnecessary loss ofliquid and the ample adjustments of cams 113 and 120 provide for varyingwidths of fabric in each chamber.

Referring now to FIGS. 6-8, in the event that the type of fabric or theliquid materials being sprayed require more than fixed nozzles in thefirst stages of either chamber 20 or 41, I may utilize an oscillatingmanifold 83 which is movable transversely by means of a motor 125mounted on a plate 126 by means of four posts 127, 127. The motor 125 isprovided with a crank 128 which drives a crosshead 129 through aconnecting rod 130. Crosshead 129 is provided with suitable guides 131and 132 4 which support the mainfold assembly 83. The crosshead 129 maybe adjustably secured to the manifold 83 by means of a clampingarrangement 133 and the manifold is provided with a suitable cap 134 forany overhang beyond crosshead 129. In this way maximum liquidpenetration of the pile yarns or fibers may be achieved and the maximumutilization of the liquid pressure to force the liquid into the fiberbase is thereby accomplished.

Referring now to FIG. 8, a modified form of breaking element will bedescribed which is employed in the event the particular fabric beingprocessed is of sufficient weight that it cannot readily be pulled overthe breaking element 31 by means of the conveyor 23. In this casestandards 81 are modified to incorporate a series of posts 140, havingcross arms 142 and opposed rollers 143, 144. A bar or tube is rotatablysupported on the series of rollers 143, 144 in such a way that the bar145 is free to rotate as the fabric F passes under the first stagenozzles 84, 84.

The beater assemblies 37, 42, and 63 are shown in more detail in FIGS.11 and 12. Each assembly comprises a platform 147 supported on legs 148,148 and having suitable cross members and braces 149, 149. A motor 150is mounted in the framework and drives the beater 40 through suitabledriving connections 151. The rollers 38 and 39 are journaled on theplatform 137 in pillow blocks 152, 152. The beater itself comprises agenerally cylindrical tube or roller 40a to which I attach by welding orotherwise transverse bars 40b and 40c to extend slightly above the levelof rollers 38 and 39. This gives ample displacement for the beatingoperation since the fabric normally sags between the rollers and thepositioning of rollers 38 and 39 is such that the normal amount of thissagging gives the desired amplitude for the beating step. It will thusbe understood that I have provided improved apparatus for liquidtreating and coloring of deep pile textile fabrics which achievescomplete penetration of the pile yarns and fibers due to the two stageliquid application and whichalso provides highly satisfactory leveldyeing results. The preliminary application of the liquids applied inchamber 20 is an important feature of the invention and these assist inachieving proper pene tration and dispersal of the color. The liquidapplied in both stages of the first chamber includes a solvent carrierand a wetting agent. Examples of such liquids are benzyl alcohol and anon-ionic wetting agent such as a polyether alcohol sold on the marketunder the name Decer'esol NI. Another satisfactory liquid for thepre-treating stage is a mixture of butyl benzoate and a non-ionicwetting agent such as an aromatic polygylcol ether sold on the marketunder the name Neutronyx 600. This pre-treating step solubilizes thedyestulf and disperses it uniformly throughout the fiber during thesteam treatment. The solvent is applied to the fabric in the first stageof chamber 20 under suflicient pressure so that the liquid actuallybounces ofi of the ground or backing portion of the fabric. Theparticular solvent or wetting agent will be chosen to avoid damage tothe fibers present in the fabric. The above chemicals in relatively weaksolutions are all satisfactory for both natural and synthetic materialsin pile fabrics. The subsequent application of the pre-treating liquidto the face of the plie of the fabric is also important in obtaining thelevel dyeing effect which is essential. It is preferred to apply thecolor to the fabric under conditions of substantially less pressure andin areas where color penetration is not actually achieved mechanicallythe liquid carriers assist the penetration so that an extremelysatisfactory and thorough dyeing result is produced. The steamingoperation completes the dispersion and transfer of the color to allparts of the fabric and also fixes the color.

Having thus described my invention, I claim:-

1. The method of continuously dyeing a textile pile fabric whichcomprises the steps of continuously passing the fabric through a firstliquid spray zone, bending the fabric at said first liquid spray zone toopen up the pile and expose the base of the pile, applying conditioningliquid to the opend up pile in said first spray zone to aid and assistin the subsequent dye penetration, continuously passing the fabricthrough a second spray zone in a straight line path and applying liquiddye under pressure to the fabric at said second spray zone byoscillating liquid dye spray means transversely across the fabric whileit is being fed.

2. The method of claim 1 in which the liquid in the first zone isapplied under greater pressure than the liquid in the second zone.

3. The method of continuously dyeing a textile pile fabric whichcomprises the steps of continuously feeding a length of pile fabricthrough a first spray zone, bending the fabric, spraying a conditioningliquid into the base of the pile in said first spray zone while in abent state, continuously passing the fabric through a second spray zone,bending the fabric in said second spray zone, spraying a dye solutiononto the fabric while in a bent state by oscillating the liquid spraydye means transversely across the fabric while it is being fed, andfurther spraying a liquid dye onto the pile of the fabric in said secondspray zone While moving in a straight line path by oscillating liquiddye spray means transversely across the fabric while it is being fed.

4. The method of continuously dyeing a textile pile fabric whichcomprises the steps of continuously feeding a length of pile fabricthrough a first spray zone, spraying a conditioning liquid against thepile side of the fabric in said first zone, thereafter continuouslyfeeding the fabric in a straight line path through a second spray zone,

spraying a second conditioning liquid onto the pile of the fabric in thesecond zone, thereafter continuously passing the fabric in a straightline path to a third spray zone and spraying a liquid dye onto the pileof the fabric in said third zone by oscillating liquid dye spray meanstransversely across the fabric while it is being fed.

References Cited by the Examiner UNITED STATES PATENTS 1,175,538 3/1916Matos.

1,198,373 9/1916 Olson 8-150 1,820,048 8/1931 Chase 8150 1,896,9542/1933 Heap 8151 1,930,853 10/1933 Kollek 8--93 2,045,755 6/1936 Cohn8151 2,199,342 4/1940 Johnson 8149.1 2,367,730 1/ 1945 Masland 81512,764,013 9/1956 Harrell 68205 2,816,811 12/ 1957 Tillett et al. 8-1482,844,019 7/ 1958 Schurrnann et al 68-205 OTHER REFERENCES Dyer, vol.120, 1958, pages 449-451.

Gokhale: J. Soc. Dyers & Col., vol. 74, pages 236-241, April 195 8.

Stevens: J. Soc. Dyers & Col., vol. 72, page 100, March 1956.

The Textile Manufacturer, November 1959, page 515.

NORMAN G. TORCHIN, Primary Examiner.

D. LEVY, Assistant Examiner.

1. THE METHOD OF CONTINUOUSLY DYEING A TEXTILE PILE FABRIC WHICHCOMPRISES THE STEPS OF CONTINUOUSLY PASSING THE FABRIC THROUGH A FIRSTLIQUID SPRAY ZONE, BENDING THE FABRIC AT SAID FIRST LIQUID SPRAY ZONE TOOPEN THE PILE AND EXPOSE THE BASE OF THE PILE, APPLYING CONDITIONINGLIQUID TO THE OPEN UP PILE IN SAID FIRST SPRAY ZONE TO AID AND ASSIST INTHE SUBSEQUENT DYE PENETRATION, CONTINUOUSLY PASSING THE FABRIC THROUGHA SECOND SPRAY ZONE IN A STRAIGHT LINE PATH AND APPLYING LIQUID DYEUNDER PRESSURE TO THE FABRIC AT SAID SECOND SPRAY ZONE BY OSCILLATINGLIQUID DYE SPRAY MEANS TRANSVERSELY ACROSS THE FABRIC WHILE IT IS BEINGFED.